Tuck-in type box



July 10, 1962 H. BLONDER 3,043,053

TUCK-IN TYPE BOX Filed March 8, 1960 2 Sheets-Sheet 1 X, 4 551 22 Ja 29x; 43s 1 6) HUM/0RD BL O/VDER l N V E N TOR ATTO'RN EYS July 10, 1962 H. BLONDER TUCK-IN TYPE BOX 2 Sheets-Sheet 2 Filed March 8, 1960 HOWARD BLONDE INVENTOR ATTORN EYS ilnited rates Patent 3,l 43,068 TUCK-IN TYPE BOX Howard Blonder, PO. Box 1082, Downey, Calif. Filed Mar. 8, 1960, Ser. No. 13,684 3 Claims. (Cl. 53-29) The invention relates to box making and has particular reference to a method of forming a tuck-in type box which is especially economical of the box board material from which the box blanks are cut.

In the box making art tuck-in type boxes form a very large percentage of all the types of boxes in use. The tuck-in type box is a conventional box wherein the blank form has a tab glued throughout its length to one of the sides to form a rectangular box, there being provided side flaps and end flaps bent inwardly and tucked in, thereby to complete the box.

The usual blank form for tuck-in boxes is an irregular shape in that one end of the blank form is invariably wider than the other in order to have the tuck-in flaps in proper relationship and this necessitates. nesting of forms in alternately opposite positions, thereby to minimize scrap to the greatest degree feasible. Even though the blank forms are thus nested, a considerable amount of waste material always is discarded at the side edges and also at end edges due to the fact that the blank form does not coincide with the edge of the commercial box board and also because the box board is limited in sheet size and proportion. The waste factor becomes considerably objectionable when high priced box boards such as glazed and metallized box boards are encountered.

Furthermore, since tuck-in boxes in modern packaging technique must substantially fit the contents to the package, the proportions and sizes are to a large extent custommade and very often only a few thousand boxes may be needed for one particular run. When just a few thousand are needed, dies must be made having relatively fewer die blanks and box board of smaller over-all sizes invariably needs to be used. Hence, the smaller the run of a particular size, the greater will be the waste at the side edges and to a degree at the end edges of the sheets of box board.

It is therefore among the objects of the invention to provide a new and improved method of forming pattern blanks for tuck-in type boxes whereby to utilize virtually the entire Width and length of sheets of box board from which the blanks are cut, thereby to minimize to the greatest degree possible the amount of scrap.

Another object of the invention is to provide a new and improved method of cutting out pattern blanks for tuckin type boxes which is especially economical of box board material and produces virtually a minimum amount of scrap on small runs of the boxes.

Still another object of the invention is to provide a new and improved method of cutting out and forming tuck-in type boxes which employs a different type ofpattern in the interest of securing a maximum amount of space within the box in proportion to the amount of material used as well as minimizing scrap.

Still further among the objectsof the invention is to provide a new and improved method of forming tuck-in type boxes which employs a pattern form economical in the amount of box board used in proportion to the capacity, which is economical of the scrap involved, and more particularly which results in a very simply formed box having a great degree of strength and which makes it possible to very handily and easily tuck in ends whereby to complete the enclosure.

With these and other objects in View, the invention consists in the method for achieving the construction, arrangement and combination of the various parts of the device whereby the objects contemplated are attained, as

hereinafter set forth, pointed out in the appended claims and illustrated in the accompanying drawings.

In the drawings:

FIGURE 1 is a plan View showing a sheet of box board from which a set of pattern blanks are cut for one particular proportionate box style.

FIGURE 2 is a perspective view of one of the boxes formed from the pattern blanks of FIGURE 1 showing one end tucked in and the other end left opened.

FIGURE 3 is a perspective view similar to FIGURE 2 showing both ends of the box tucked in.

FIGURE 4 is a planview of a sheet of box board showing pattern blanks die cut therefrom of different proportionate dimensions and having a different type of tuck-in tab.

FIGURE 5 is a perspective view of a box formed from one of the pattern blanks of FIGURE 4 with one end only tucked in.

FIGURE 6 is a perspective view similar to FIGURE 5 showing both ends tucked in.

In an embodiment of the invention chosen for the purpose of illustration there is shown a sheet 10 of box board of conventional breadth and indefinite length having side edges 11 and 12. By way of example four pattern blanks are shown indicated by the reference characters 13, 14, 15 and 16, although it will be appreciated that as many blanks may be cut along the length of the box board as the multiple capacity of the die may accommodate and the length of the box board may permit.

It will be noted that the pattern blanks are identical and identically oriented so that a description of one will sufiice for all. By way of example, the blank 15 is shown as comprising a central portion 17 rectangular in shape, long side walls 18 and 19, respectively, short side walls 20 and 21, respectively, cover walls 22 and 23, respectively, tuck-in flaps 24 and 25, respectively, and four side flaps indicated respectively by the reference characters 26, 27, 28 and 29.

In this particular box the proportion is somewhat specific in that the width is about 1 /3 of the length, the height of the side wall is about of the width, and the over-all breadth of the cover flaps is very slightly greater than the breadth of the central portion.

When the pattern blanks are die cut, the side flaps are cut loose along lines 30 where they join the short side walls and scored along the long lines 31 where they join the long side walls.- Otherwise, the central portion, side walls, cover walls, tuck-in flaps and side flaps are separated by scored lines which remain uncut. In this particular box size there is a slight amount of scrap formed from the triangular pieces 32 and 33 which are 7 the cut-off tips of the originally triangular cover walls to leave the remaining breadth of the cover walls slightly less than the short dimensions of the central portion. Also very small triangular pieces 34, 35, 36 and 37 are cut out forming a negligible amount of scrap, the cutout pieces, however, leaving spaces helpful in the final handling of the blank when folded into the form of a box 40, as illustrated in FIGURES 2 and 3.

It will be understood from the drawing and description that side edges 41 and 42 of adjacent pattern blanks 13 and 15 form one continuous line and that the only scrap at that line is that formed by one tip piece of each cover wall and the negligible pieces 36 and 37 of each. It will also be noted that sides 43 and 44, respectively, of pattern blanks 15 and 16 form one continuous edge coincident with the edge of the box board 10 and that a similar minimum of scrap is there cut out. Likewise sides 45 and 46 of the pattern blanks 13 and 14 are in alignment with each other and coincide with the side edge 11 of the box board, and this position results in a similar rninimium amount of scrap.

a 11' and 12'.

When one of the pattern blanks is freed from the box board, it is folded in the manner illustrated in FIGURE 2 along the scored lines and cover wall 23 is folded to a position overlying the cover wall 22 leaving overlapped areas 47 and 43 where glue or other appropriate adhesive is applied to glue the cover walls together in perfect box shape. It will be noted that only a relatively small amount of glue need be applied and that the overlapped portions form but a small-percentage of the box area.

After this has been accomplished, tuck-in flap 24 is tucked underneath the cover walls 22 and 23, after which the box can be filled. Subsequently tuck-in flap 25 is similarly tucked in after the side flaps 28 and 29 are tucked in and the box is complete, as shown in FIGURE 3. The box 40 thus resulting is a firm, well constructed box which can be-easily closed by the tucking in of the tuck-in flaps and when completed is rugged at the corners and presents a maximum number of clean faces of the side walls and central portion, leaving only one face to accommodate theutilitarian features of gluing and tuckmg in. V

' In the form of invention illustrated in FIGURE 4, a similar sheet of box board 10 isshown having side edges In this form of the device there is shown by way of example pattern blanks 59, 51, 52 and 53 symmetrically arranged and oriented on the box board sheet 10' and identical in shape, proportion and form to the extent that a description of one will sutfice for both.

Making reference by way of example to the pattern blank 53, there is shown a central portion 54, long side walls 55 and 56, short side walls 57 and 58, cover walls 59 and 60, tuck-in flaps 61 and 62, and four side flaps 63, 64, 65 and 66. I

'It will be noted in this form also of the pattern blank the central portion which determines the two dimensions of the ultimate box 70, indicated in FIGURES'S and 6, is a long rectangle in proportion with the long dimension about 1% the length of the short dimension. A slightly different proportion, however, prevails in the height of the box in that the height of the side walls is about A of the short dimension of the'central portion. The cover flaps have a breadth very slightly less than the short dimension of the central portion so that no tips need to be cut from the cover walls.

To provide a particularly strong box at the corners, the

side flaps in each instance are scored along central lines 67 in a direction reverse with respect to the scoring along 7 lines 68 and 69. Except for the scoring along lines 67, the central portion, side walls, cover walls, tuck-in flaps and side flaps are separated respectively by scoring of the blank and comprise virtually a negligible amount.

of'scrap on all sides as well as along the side edges 11' and 12' of the box board A similar minimum amount of scrap will also be formed at the beginning and end of the box board 10'.

In forming the box 70 from one or another of the pattern blanks, the cover wall 59, for example, is folded over opposite cover wall 60 to provide overlapping portions 79 and 80, respectively, where a diamond shaped patch of glue sufiices for the entire gluing operation. Thereafter tuck-in flap 62 is bent and ed beneath the cover walls 59 and 60 in the position illustrated in FIGURE 5, during which operation the side flaps 63 and 66 are bent inwardly, folding along the score lines 67 "of each and along the score lines 68 and 69 of each in the opposite direction. Formed to thisextent the box may be filled and thereafter the tuck-in flap 61 is folded over and tucked in to the position illustrated in FIGURE'6. During this operaion also the side flaps 64 and 65 are pushed inwardly folding in one direction along core lines 67 and also folding along score lines 68 and 69 in the opposite direction. This folding technique at the corners provides an especially strong corner without, however, impairing the ease of manipulation of the box and particularly without increasing in any sense the amount of scrap box board which might result. The box 70 also is extremely economical in theamount of box board in proportion to the space provided in the finished box.

A comparison between the pattern blank method herein described and the nesting methods used for conventional tuck-in type rectangular boxes reveals savings in scrap from twenty percent to twenty-nine percent, depending upon the number of pattern blanks which are cut from a given width and length of box board by the dieoperations. It will be appreciated-that in using applicants method, there is a greater degree in saving over the conventional method when smaller numbers of pattern blanks are cut out at each operation but that even for large numbers, there is an appreciable saving.

There has accordingly been described herein a method which is demonstrably economical of box bOEUl'd and which produces a very desirable type of tuck-in box using virtually a minimum amount of board material with respect to the aggregate space formed when the box is complete.

While the invention has herein been shown and 'described in what is conceived to be the most practical and preferred embodiment, it is recognized that departures may be made therefrom within the scope of the invention, which is not to be limited to the details disclosed herein but is to be accorded the full scope of the claims so as to embrace any and all equivalent structures and methods.

Having described my invention, what I claim as new and desire to secure by Letters Patent is:

1. A method of forming tuck-in boxes from a rectangular running length of box board comprising the steps of:

(a) dividing said running length into a' plurality of rectangular pattern blanks wherein the width of the box board accommodates at least one pattern blank placed on the box board so that the sides of the pat tern blank are parallel to edges of the box board;

(b) forming fold lines in each pattern blank to define a bottom face, two side walls, two cover face portions, two end walls, two tuck-in flaps integral with the end walls respectively, and four side flaps integral with the ends respectively of the side walls,

(i) said fold lines being formed to define the outline of the pattern blank such that its bottom face has its longitudinal and transverse axes aligned with respective diagonals of the pattern blank,

(ii) the end walls being coextensive and integral with the bottom face along opposite end' edges respectively of the bottom face,

(iii) the side walls beinglcoextensive and integral with the bottom face along opposite side edges respectively of the bottom face,

(iv) the two tuck-in [flaps being members respectively of one pair of diagonally opposed corner portions of each pattern blank and being coextensive and integral along one edge thereof with said end walls respectively,

(v) the two cover face portions being members respectively of the other pair of diagonally opposed corner portions of each pattern blank and being coextensive and integral along one edge thereof with the side walls respectively, the linear length of each cover face portion from the edge of the side wall to the corner of the pattern blank being sufficient to provide an overlapping gluing portion;

(0) folding said sheet along two of said fold lines to overlap the gluing portions of the cover face portions;

(d) gluing said overlapped portions together and maintaining said cover face portions adjacent the bottom face; 7 V

(e) shaping the glued sheet to the configuration of a right prism; r

(1) placing matter to be contained by the box between the bottom face and the cover face portions; and

(g) closing the box by inserting the tuck-in flaps to extend in a plane under the cover face portions and to be free of the cover face portions and each other.

2. A method according to claim 1 and comprising the step of creasing said side flaps from the point most nearly adjacent the bottom face outwardly whereby to divide each said side flap into equal portions, and bending said side flaps inwardly along the lines of said creasin to form reinforced corners of the box.

3. A method according to claim 1 in which the length of said rectangular bottom face is between about 160% 6 to 166% of the width thereof and the width of said side walls is between about 11% and 70% of the width of said rectangular bottom face.

References Cited in the file of this patent UNITED STATES PATENTS 1,774,299 Stubbs et a1 Aug. 26, 1,944,794 Klinger Jan. 23, 2,238,468 Hayden Apr. 15, 2,565,944 Bergstein Aug. 28,

FOREIGN PATENTS 781,274 France May 11, 

